Replacing Wires and Plugs

[Chris101]

I'm trying to replace the wires and plugs on my '97 Astro, and I'm not entirely sure how to get to them. Do I need to get under the van and do it by just feeling around, or is there some other way?

[tableman]

Well first take off the dog house, then one side at a time, jack up the front and take off the front wheel, you kind have to work from inside and under to get to everything. It helps alot if you have a set of those wiggle extensions for you rachet, rather then the flexiable extension elbows. It can be done in less then 2 hours, just make sure all the spark plug wires are back in their holders or they might rub against the heat sheild of the dog house and cause a miss fire. Good Luck

[Chris101]

When you say 'dog house', I'm assuming you mean the middle console (cup holders, glove box). How do I get that out of there? Do I just unscrew those two screws and pull on it? I picked up a service manual, and it shows it disasembled, but doesn't say how to get it off.

[tableman]

It is kind of hard to describe, but I will try.
1st you take of your inner console, you might have a coffee cup holder and glove box on it. this is done by 2 screws at the top left and right side. Then if you pull the carpet back at the bottom you will see 2 nuts, you will need a rachet with an extension to get these. Once you have these off pull the console back, unplug any wire harness that might be there.
2nd Now there maybe a heating duct that runs the heat to the floor in front of the engine cover, remove duct by pulling and wiggling it out of position.

3rd the engine cover is held on by 2 bolts at the top where it attaches to the fire wall, you will need at least 10inches worth of extensions to reach these bolts. These bolts are captive so they stay in place when loosed off.

4th there are 2 clamps that hold the engine cover at the bottom, between the two front seats, that are held in place by 2 nuts, remove these clamps and engine cover is free. Make sure both seats are slid back as far as they go, then slide the engine cover back and swing it to the drivers side twilt back and hold your tongue the right way and the engine covers come out.

Hope this helps good luck

[Kings-x59]

I just replaced mine recently. Working space is tight to be sure.
I managed to get to the passenger side plugs and wires from inside the van with the engine cover (dog house) removed. The drivers side plugs and wires I couldn't quite manage to do from inside. I found it easier to do them from underneath the van. Either way, it was pretty much a blind operation. I never could quite get a vantage point to see what I was doing.
If your new wires don't already have dielectric grease in the boots, I highly recommend getting some. It will make the next replacement a lot easier. I've had wire boots literally weld themselves to old spark plugs.

[cooncatbob]

Also put antisieze on the sparkplug threads, and use a long life plug like a Bosch Platinum.